Aircraft Sensor Mounting Carrier Flush Aerodynamic Integration
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Solution Overview
Problem
The integration of aerodynamic sensors, such as static pressure load cells, into aircraft structures faces challenges due to high tolerances in fibre-reinforced composite materials, leading to measurement errors and malfunctions, particularly in terms of pressure sealing integrity and thermal sealing, which affect the aerodynamic surface continuity and operational reliability.
Innovation Solution
A component arrangement featuring a mounting structure connected to the aircraft structure with a component carrier that acts as an aerodynamic plate, ensuring minimal tolerance between components, optimized thermal coupling, and reduced component count, allowing for precise assembly and maintenance, while also serving as a stiffening element to enhance aerodynamic flow and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple components with high tolerances are used in the mounting structure, then the component count is reduced, but the pressure sealing integrity deteriorates
Solution Approach 1:
The mounting structure is divided into separate components: a mounting structure attached to the aircraft skin, and a separate component carrier that interfaces with the sensor. This segmentation allows each component to be manufactured with standard tolerances while maintaining overall sealing integrity through the sealing ring design.
Solution Approach 2:
A sealing ring is introduced as an intermediary element between the mounting structure and the component carrier. This sealing ring compensates for tolerance accumulations and ensures pressure sealing integrity without requiring high manufacturing precision on the structural components.
2Ease of manufacture
If high tolerances on component thickness are accepted, then manufacturing cost is reduced, but measurement precision deteriorates
Solution Approach 1:
The component carrier is designed with a localized precision surface that interfaces directly with the sensor. Only this specific local area requires high precision, while the rest of the mounting structure can be manufactured with standard tolerances. This approach maintains measurement precision while reducing overall manufacturing cost.
3Weight of moving object
If the aerodynamic plate is made thinner to reduce weight, then weight is reduced, but structural strength deteriorates
Solution Approach 1:
The aerodynamic plate is constructed using composite materials that provide high strength-to-weight ratio. This allows the plate to be made thinner for weight reduction while maintaining the necessary structural strength through the inherent properties of composite materials.
4Ease of operation
If the number of components is reduced, then assembly complexity is reduced, but assembly precision deteriorates
Solution Approach 1:
The component carrier incorporates self-aligning features and self-centering mechanisms that automatically compensate for minor positioning variations during assembly. This allows for simpler assembly procedures while maintaining high assembly precision without requiring complex alignment procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution achieves improved sealing integrity, reduced weight, and enhanced operational reliability by minimizing component tolerances, ensuring uninterrupted aerodynamic flow, and simplifying maintenance, thereby addressing the issues of measurement errors and malfunctions in aerodynamic sensor installations.
Implementation Method 1
an end face of the projection on the component, via a thermally effective seal (52), abuts against a contact face (54) of the component carrier (8)
Data Source
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AI summary
Disclosed is a component arrangement on an aircraft structure (2), in particular on a fuselage structure of an aircraft (4), with at least one mounting structure (6) connected with the aircraft structure (2), and at least one component (10) to be assigned to the aircraft structure (2), in particular a measuring device. In accordance with the invention at least one component carrier (8) is provided for the reception of the component (10) to be mounted, wherein the component carrier (8) can be connected with the mounting structure (6), and an outer surface (24) of the component carrier (8), facing away from the component (10), extends approximately flush with an outer surface of the aircraft structure (2). Also disclosed is a method for the Installation of a component (10) into an aircraft structure (2) with a mounting structure (6), wherein the component (10) is connected with the mounting structure (6) via a component carrier (8), and an outer surface (24) of the component carrier (8), facing away from the component (10), extends approximately flush with an outer surface of the aircraft structure (2).